Light emitting diode headlamp

ABSTRACT

A light emitting diode headlamp capable of low beam and high beam functions. The light emitting diode headlamp assembly comprises high-flux light emitting diodes, a reflector subassembly, a first and second light transmissive member, and a heat sink.

PRIORITY CLAIM

The present application claims priority to U.S. Provisional PatentApplication Ser. No. 60/414,980, filed Oct. 1, 2002, and U.S.Provisional Patent Application Ser. No. 60/507,621, filed Sep. 30, 2003,both of which are incorporated by reference herein in their entireties.

FIELD OF THE INVENTION

The subject invention relates to vehicular lights. More particularly,the embodiments of the subject invention are directed to a headlamp andheadlamp assembly for vehicles that uses light emitting diodes as alight source.

BACKGROUND OF THE INVENTION

Most motorized vehicles currently use incandescent or high-intensitydischarge sealed-beam headlamps and headlamp assemblies. The embodimentsof the subject invention are designed to retrofit the currentincandescent sealed-beam headlamps and headlamp assemblies. For example,many heavy-duty vehicles use four (4) inch by six (6) inch, rectangular,sealed-beam headlamps in a quad lamp assembly. In one embodiment of thepresent invention, four (4) inch by six (6) inch, rectangular,sealed-beam low beam and high beam headlamps, that use light emittingdiodes as a light source, form a quad lamp assembly designed to retrofitthe incandescent four (4) inch by six (6) inch quad packages. By way offurther example, other vehicles use seven (7) inch round, sealed-beamheadlamps in a dual lamp assembly. Therefore, in an alternate embodimentof the invention, seven (7) inch round, sealed-beam combined low/highbeam headlamps, that use light emitting diodes as a light source, form atwo-lamp assembly designed to retrofit the incandescent, seven (7) inchround packages.

The embodiments of the subject invention that are disclosed herein aredesigned to satisfy the Society of Automotive Engineers (SAE) StandardJ1383 for high beam and low beam vehicular headlamps. SAE Standard J1383specifies certain photometric requirements, including luminous intensityrequirements, for vehicular lamps functioning as headlamps.

The Department of Transportation (DOT), in its Federal Motor VehicleSafety Standards, 49 C.F.R. §571.108 (2000), (“FMVSS 108”) regulates alllamps, reflective devices, and associated equipment. FMVSS 108 can befound at www.nhtsa.dot.gov and is hereby incorporated by reference inits entirety. DOT Standard 1383 (part of FMVSS108) adopts the Society ofAutomotive Engineers (SAE) Standard J1383 (December 1996) for motorvehicle headlamps.

SAE Standard J1383 defines a headlamp as a “lighting device providing anupper and/or lower beam designed to provide illumination forward of thevehicle.” SAE Standard J1383 further defines a sealed beam headlampassembly as “a headlamp assembly which includes one or more sealed beamheadlamps.” A low beam is a “beam intended to illuminate the road aheadof a vehicle when meeting or following another vehicle.” A high beam isa “beam intended primarily for distant illumination for use when notmeeting or following other vehicles.” SAE Standard J1383 also requiresthat the color of the emanating light produced by a headlamp shall bewhite as defined in SAE Standard J578.

SAE Standard J1383 also specifies certain requirements for vehicularlamps functioning as headlamps, including minimum and/or maximumluminous intensity requirements. According to the aforementionedstandards, a minimum and/or maximum luminous intensity must exist atvarious points in the illumination zone to be in compliance. Thesespecific photometric requirements for vehicular low beam and high beamheadlamps, as set forth in SAE Standard J1383, are included hereinbelow.

TABLE 1 PHOTOMETRIC SPECIFICATION - LOW BEAM Low Beam Minimum (cd)Maximum (cd) 10 U to 90 U, 45° R to 45° L 125 8 L to 8 R, H to 4 U 64 4L to 4 R, H to 2 U 125 1 U to 1-½ L to L 700 ½ U to 1-½ L to L 1000 ½ Dto 1-½ L to L 3000 1-½ U to 1 R to R 1400 ½ U to 1 R, 2 R, 3 R 2700 ½ Dto 1-½ R 8000 20000 1 D to 6 L 750 1-½ D to 2 R 15000 1-½ D to 9 L and 9R 750 2 D to 15 L and 15 R 700 4 D to 4 R 8000

TABLE 2 PHOTOMETRIC SPECIFICATION - HIGH BEAM High Beam Minimum (cd)Maximum (cd) 2 U to V 1500 1 U to 3 R and 3 L 5000 H to V 20000 75000 Hto 3 R and 3 L 10000 H to 6 R and 6 L 3250 H to 9 R and 9 L 2000 H to 12R and 12 L 500 1-½ D to V 5000 1-½ D to 9 R and 9 L 1500 2-½ D to V 20002-½ D to 12 R and 12 L 750 4 D to V 12500 Maximum Beam Candela⁽¹⁾ 30000⁽¹⁾The highest candela reading found in the beam pattern

SAE J578, entitled “Color Specification”, sets forth the definition forwhite light as applied to headlamps. The definition applies to theoverall effective color of light emitted by a headlamp in any givendirection and not to the color of the light from a small area of thelens. In SAE J578, the fundamental requirements for color are expressedas chromaticity coordinates according to the CIE (1931) standardcolorimetric system.

Pursuant to SAE J578, the following requirements for white light shallapply when measured by the tristimulus or spectrophotometric methods, asare well known in the art.

TABLE 4 WHITE LIGHT (ACHROMATIC) The color of light emitted from theheadlamp shall fall within the following boundaries: x = 0.31 (blueboundary) x = 0.50 (yellow boundary) y = 0.15 + 0.64x (green boundary) y= 0.05 + 0.75x (purple boundary) y = 0.44 (green boundary) y = 0.38 (redboundary)

SAE J1383 standard and SAE J578 standard can also be found atwww.sae.com and are hereby incorporated by reference in their entirety,as is FMVSS 108, 49 C.F.R. §571.108 (2000).

As mentioned above, one embodiment of the subject invention relates to aheadlamp quad assembly that incorporates four (4) individual headlamps(i.e. 2 low beam lamps and 2 high beam headlamps). In this embodiment,each individual headlamp is a four (4) inch by six (6) inch, rectangularsealed-beam lamp. In an alternate embodiment, a dual headlamp assemblyincorporates two (2) combined, high/low beam headlamps, wherein eachindividual headlamp is a seven (7) inch round sealed-beam lamp. In stillanother embodiment of the two-lamp assembly, each individual headlamp isa five (5) inch by seven (7) inch rectangular sealed-beam lamp. In eachof the embodiments, the individual lamps forming a headlamp assemblyemit white light (as defined above).

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagrammatic, front-end view of a heavy-duty vehicleprovided with a light emitting diode headlamp assembly according to oneembodiment of the present invention.

FIG. 2 is an exploded perspective view of a low beam headlamp accordingto one embodiment of the present invention.

FIG. 3 shows a vertical cross section of the low beam headlamp in FIG.2.

FIGS. 4A–4C illustrate a cross-sectional, perspective and plan view,respectively, of a reflector subassembly according to one embodiment ofthe present invention.

FIG. 5A illustrates a vertical cross-sectional view of inner and outerlight transmissive members according to one embodiment of a low beamheadlamp.

FIG. 5B illustrates a longitudinal cross-sectional view of inner andouter light transmissive members according to one embodiment of the lowbeam headlamp.

FIGS. 5C–5D illustrate a perspective and top plan view of the innerlight transmissive member shown in FIGS. 5A–5B.

FIG. 6 shows a rear plan view of the outer light transmissive member forthe low beam headlamp shown in FIGS. 1–2.

FIGS. 7A–7F illustrate partial longitudinal and vertical cross-sectionsof to the optical surfaces formed on the outer light transmissive membershown in FIG. 6.

FIG. 8 illustrates a longitudinal cross-sectional view of inner andouter light transmissive members according to one embodiment of the highbeam headlamp illustrated in FIG. 1.

FIG. 9 shows a rear plan view of the outer light transmissive member forthe high beam headlamp illustrated in FIG. 1.

FIGS. 10A–10B show partial longitudinal and vertical cross-sections ofthe optical surfaces formed on the outer light transmissive member shownin FIG. 9.

FIGS. 11A–11C illustrate a top plan view, bottom plan view andcross-sectional view, respectively, of the housing in one embodiment ofthe headlamp assembly.

FIG. 12 illustrates one embodiment of the drive circuit in oneembodiment of the headlamp assembly.

FIG. 13A illustrates the manner in which the reflector subassembly andinner light transmissive member direct light emitted from the lightemitting diodes.

FIG. 13B illustrates the manner in which the outer light transmissivemember in a high beam headlamp directs light.

FIG. 14 is a diagrammatic, top plan view of the vehicle in FIG. 1.

FIGS. 15A–15B illustrate the light pattern created on an imaginarysurface.

FIGS. 16A–C illustrate an alternate embodiment of the invention, a7-inch round combined low/high beam headlamp.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

For the purpose of promoting an understanding of the present invention,references are made in the text hereof to embodiments of a low beam andhigh beam light emitting diode headlamp and headlamp assembly, some ofwhich are illustrated in the drawings. It is nevertheless understoodthat no limitations to the scope of the invention are thereby intended.One of ordinary skill in the art will readily appreciate thatmodifications such as these involving the shape of the low and high beamheadlamps, type or number of light emitting diodes, number of reflectorunits, or type and placement of optical elements of the lens, do notdepart from the spirit and scope of the present invention. Some of thesepossible modifications are mentioned in the following description. Inthe embodiments depicted, like reference numerals refer to identicalstructural elements in the various drawings.

FIG. 1 is a diagrammatic, front-end view of a heavy-duty vehicle 1provided with a preferred embodiment of the present invention, namely asealed beam headlamp assembly 4 that uses light emitting diodes as alight source. In the embodiment shown here, headlamp assembly 4 is afour (4) inch by six (6) inch, quad headlamp package. Accordingly, asshown here, headlamp assembly 4 comprises four individual sealedheadlamps: two (2) low beam headlamps 70 and two (2) high beam headlamps170, each of the four individual headlamps utilizing light emittingdiodes as a light source. In this embodiment, the low and high beamheadlamps are identical, except for the outer lens that distributes thelight appropriately to satisfy the SAE requirements.

In the embodiment shown in FIG. 1, and as described herein, headlamps 70function as low beam headlamps that satisfy the photometric,dimensional, color and other requirements for low beam headlamps as setforth in SAE Standard J1383. Similarly, headlamps 170 function as highbeam headlamps that satisfy the photometric, dimensional, color andother requirements for high beam headlamps as set forth in SAE StandardJ1383. For example, in the embodiment shown here, low beam headlamps 70and high beam headlamps 170 are rectangular in shape and approximatelyfour (4) inches by six (6) inches to comply with the dimensionalrequirements of SAE Standard J1383. One of ordinary skill in the artwill readily appreciate, however, that a sealed-beam headlamp assemblyaccording to the instant invention can also comprise combined low/highbeam headlamps with alternate shapes and/or dimensions and still complywith SAE Standard J1383. For example, in one alternate embodiment, aheadlamp assembly utilizes two combined low beam/high beam headlampsthat are round in shape with a seven (7) inch diameter (see FIGS.16A–C). Alternatively, the headlamp assembly utilizes two combined lowbeam/high beam headlamps that are rectangular in shape and approximatelyfive (5) inches by seven (7) inches (not shown).

Moreover, the overall effective color of light emitted by low beamheadlamps 70 and high beam headlamps in any given direction is white tosatisfy SAE Standard J1383. As indicated hereinabove, SAE Standard J578expresses the fundamental requirements for white light as chromaticitycoordinates according to the CIE (1931) standard colorimetric system(see Tables 3–4 above).

Referring further to FIG. 1, in an embodiment of the quad headlampassembly, two (2) headlamps 70 are operatively arranged as the two outerheadlamps of headlamp assembly 4 to perform the low beam function andtwo (2) headlamps 170 are operatively arranged as the two innerheadlamps of headlamp assembly 4 to perform the high beam function.Referring further to FIG. 1, each low beam headlamp 70 and each highbeam headlamp 170 is a separate unit with a separate housing that ismounted individually to the front end of vehicle 1, thereby formingheadlamp assembly 4. However, in alternate embodiments of the invention,headlamp assembly 4 can comprise low beam headlamp 70 and high beamheadlamp 170 as separate units that are joined together prior tomounting or each pair of low beam headlamp 70 and high beam headlamp 170can share a single housing. The method and manner of mounting headlampassembly 4 to vehicle 1 are well known to one of ordinary skill in theart.

FIG. 2 is an exploded perspective view of an individual low beamheadlamp 70. Low beam headlamp 70, in this embodiment of the invention,is comprised of a housing 6, a reflector subassembly 11, a plurality ofhigh-flux light emitting diodes 12, an outer light transmissive member13, and a planar substrate 9. Headlamp 70 further comprises a pluralityof inner light transmissive members 17, disposed behind outer lighttransmissive member 13 (and, therefore, not shown here). A drive circuit5, discussed in more detail hereinbelow, is also provided for headlamp70.

In FIG. 2, headlamp 70 is shown to include a total of six (6) high-fluxlight emitting diodes 12. In this embodiment, light emitting diodes 12are configured in a two-dimensional array having two horizontal rows andthree vertical columns to create a 2×3 matrix. In this embodiment, lightemitting diodes 12 are mounted on planar substrate 9 with their primaryaxis horizontal to the ground and parallel with the longitudinal axis ofvehicle 1, such that the light emitted from each of light emittingdiodes 12 is directed away from planar substrate 9. In an alternateembodiment of a combined high/low beam headlamp, light emitting diodes12 are configured in a circular pattern and mounted on a circular planarsubstrate (See FIG. 16C).

In all of the embodiments disclosed herein, a high-flux light emittingdiode is defined as a light emitting diode capable of producing aminimum flux of at least 50–55 lumens, and an average flux ofapproximately 70 lumens. For example, but not intending to be limiting,a plurality of 3-Watt Luxeon™ Lambertian-style light emitting diodes,manufactured by LumiLeds Lighting B.V., are used.

FIG. 3 shows a cross section along axis A—A (see FIG. 2) of low beamheadlamp 70. Referring to FIG. 3, headlamp 70 includes housing 6 andouter light transmissive member 13. In this embodiment, and as will bedescribed in more detail below, outer light transmissive member 13 is alens with at least one optical surface for directing light emitted fromlight emitting diodes 12. Outer light transmissive member 13 alsofunctions to form a cover for housing 6, defining a three-dimensionalspace 7 therebetween. In the embodiment shown in FIG. 3, outer lighttransmissive member 13 is hermetically sealed to housing 6 with anadhesive that additional functions as a sealant. For example, one ofordinary skill in the art will readily appreciate that RTV silicone orurethane can be used as the adhesive.

Referring further to FIG. 3, headlamp 70 again is shown to comprisereflector subassembly 11, high-flux light emitting diodes 12, and planarsubstrate 9. Headlamp 70 is also shown to include a plurality of innerlight transmissive members 17 fixedly secured to light transmissivemember 13.

In FIG. 3, it can be seen that light emitting diodes 12 are disposed atthe base of reflector subassembly 11 and mounted to planar substrate 9.Planar substrate 9 is a circuit board in the embodiment shown here. Morespecifically, planar substrate 9 is an aluminum core circuit board thatis mounted directly on housing 6.

In alternate embodiments, planar substrate 9 can be a conventionalcircuit board. In such an embodiment (not shown), light emitting diodes12 are secured to planar substrate 9 via mounting posts with heattransfer properties, wherein the mounting posts correspond to holes inplanar substrate 9. Such a mounting method is described in U.S. Pat. No.5,857,767 (Hochstein), U.S. Pat. No. 6,428,189 (Hochstein) and U.S. Pat.No. 6,582,100 (Hochstein). In still another embodiment, a very thinFiberglass Reinforced Polyester circuit board can be used as planarsubstrate 9, which would provide adequate heat transfer away from lightemitting diodes 12 and, thereby, eliminate the need for an aluminumcircuit board or mounting posts.

FIG. 4A illustrates a cross-sectional view of reflector subassembly 11.FIG. 4B illustrates a perspective view of reflector subassembly 11. FIG.4C illustrates a top planar view of reflector subassembly 11. In theembodiment shown in FIGS. 4A–4C, reflector subassembly 11 is a unitaryreflector subassembly. Reflector subassembly comprises a plurality ofreflector units 11 a arranged in a plurality of rows. Each individualreflector unit 11 a has an aperture 26, which corresponds to one lightemitting diode 12. Specifically, reflector subassembly comprise six (6)reflector units 11 a forming a 2×3 array such that each individualreflector unit 11 a corresponds to an individual light emitting diode12. In an alternate embodiment of a combined high/low beam headlamp,reflector subassembly combines fourteen (14) individual reflector unitsforming a circular arrangement such that each individual reflector unitcorresponds to one of fourteen (14) individual light emitting diodes(see FIGS. 16A–C).

In the embodiment shown, each individual reflector unit 11 a is aparabolic revolution with a 6 mm focal length. More specifically, butnot intended to be limiting, in the embodiment shown here, distance G—Gis approximately 44 mm; distance F—F is approximately 44 mm, and eachaperture 26 has a diameter of 24 mm. More generally, each reflector unit11 a collects and collimates a portion of the light emitted from thecorresponding light emitting diode 12 (see FIG. 13A). The resultinglight rays are substantially parallel to the longitudinal axis of thelamp and directed toward the outer light transmissive member (not shownin FIGS. 4A–4C).

In the embodiment shown, reflector subassembly 11 is constructed of ametalized thermoplastic material. Specifically, reflector subassembly 11is a single piece of molded polycarbonate plastic that is subsequentlymetalized with aluminum. In alternate embodiments, reflector subassembly11 can be constructed of a naturally reflective material, or can becoated with other reflective materials, such as white or silver paint.In addition, although the embodiment shown here depicts a unitaryreflector subassembly with six reflector units, in an alternateembodiment each reflector unit 11 a can be molded as a plurality ofindividual reflectors.

FIG. 5A illustrates a cross section of outer light transmissive member13 along vertical line A—A, as shown in FIG. 2, and FIG. 5B illustratesa cross section along longitudinal line B₂—B₂. As can be seen in FIGS.5A–5B, light transmissive member 13 has an inner surface 21 and outersurface 22.

A plurality of annular extensions 20 corresponding to light emittingdiodes 12 are integral to outer light transmissive member 13, extendinglaterally from inner surface 21 toward reflector subassembly 11. Eachannular extension 20 functions as an alignment mechanism for an innerlight transmissive member 17. In the embodiment shown, there are six (6)annular extensions 20 and six (6) inner light transmissive members 17,each corresponding to one of the six (6) light emitting diodes 12. Innerlight transmissive members 17 are fixedly secured (as described below)to annular extensions 20 to maintain the correct position relative toone (1) corresponding light emitting diode 12. More specifically,annular extensions 20 align each inner light transmissive member 17relative to one (1) light emitting diode 12 such that each inner lighttransmissive member 17 is positioned substantially parallel to outerlight transmissive member 13 and in front of one (1) corresponding lightemitting diode 12.

In alternate embodiments, other alignment mechanisms for lighttransmissive members 17 may be used. For example, although not shown,one could use three-legged extensions that laterally extend toward thereflector subassembly or disc-like extensions from the outer lighttransmissive member that laterally extend toward the reflectorsubassembly. In addition, one could use a plurality of annularextensions or three-legged extensions that lateral extend from theplanar substrate (not shown).

Inner light transmissive members 17 are collimating lenses with a 24 mmback focal length. FIGS. 5 c–5 d illustrate a perspective andcross-sectional view of one light transmissive member 17, respectively.Each inner light transmissive member 17 captures the light rays thatbypass reflector units 11 a, and then concentrates and directs thecaptured light rays toward outer light transmissive member 13. Morespecifically, each inner light transmissive member 13 captures the lightrays emitted in a cone extending approximately forty-four (44) degreesfrom a corresponding light emitting diode 12. In the embodiment shownhere, each light transmissive member 17 is an aspheric lens that isoperatively mounted to outer light transmissive member 13 via annularextensions 20. In one embodiment, each light transmissive member 17 isfixedly secured to an annular extension 20 via a snap-lock mechanism. Inalternate embodiments, inner light transmissive members 17 can each befixedly secured to annular extensions 20 via ultrasonic welding,ultrasonic swaging, heat staking, or adhesives.

In one embodiment, outer light transmissive member 13 is formed of asingularly molded piece of clear, polycarbonate plastic. Similarly,inner light transmissive members 17 are formed of a molded piece ofclear, polycarbonate plastic.

FIG. 6 shows a rear top plan view of outer light transmissive member 13as provided in low beam headlamp 70. Referring to FIG. 6, longitudinalaxis of headlamp 70 is defined as line B₁—B₁, and vertical axis ofheadlamp 70 is defined as line A—A.

As can be seen, in this embodiment outer light transmissive member 13 isa lens with a plurality of individual prism optics 25 a,b,c forming arectangular array on inner surface 21. By varying the radius, curvature,or thickness of the individual prism optics 25 a,b,c, different desiredlight patterns can be achieved to satisfy the photometric andluminescence requirements for low beam headlamps as set forth in SAEStandard J1383. For example, in the embodiment shown in FIG. 6, outerlight transmissive member 13 has three distinct optical surfaces formedon inner surface 21. The upper portion above longitudinal axis B₁—B₁ hasoptical surface 80 and optical surface 81, and the lower portion belowlongitudinal axis B₁—B₁ has optical surface 90. In general, opticalsurface 80 uniformly spreads the light in the horizontal direction at awide angle, approximately 25–30 degrees left and right of vertical axisA—A. Optical surface 81 spreads the light horizontally in a narrowpattern and vertically, to produce a light pattern approximately eight(8) degrees left to eight (8) degrees right of vertical axis A—A andapproximately zero (0) degrees to four (4) degrees up from longitudinalaxis B₁—B₁. Finally, optical surface 90 spreads the light bothvertically and horizontally, to produce a light pattern approximatelytwo (2) degrees down from longitudinal axis B₁—B₁ and approximately two(2) degrees right of vertical axis A—A. In this way, optical surface 90produces a high intensity area below and to the right of center asrequired by SAE Standard J1383.

More specifically, but not intending to be limiting, in the embodimentshown in FIG. 6, optical surface 80 comprises a plurality of prismoptics 25 a; optical surface 81 comprises a plurality of prism optics 25b; and optical surface 90 comprises a plurality of prism optics 25 c.

In FIG. 7A, a portion of optical surface 80 is shown in longitudinalcross-sectional view (along line B₃—B₃). Prism optics 25 a preferablyhave a longitudinal cross sectional profile that is generally convextoward light emitting diodes 12. More specifically, as shown here, thelongitudinal cross section of prism optics 25 a has a radius ofcurvature that is approximately 2.804 mm. In FIG. 7B, a portion ofoptical surface 80 is shown in vertical cross-sectional view (along lineA—A). In the embodiment shown here, prism optics 25 a have a verticalcross-sectional profile that is generally linear with a decline angle mequivalent to approximately 2.950 degrees down from the horizontal. Oneof ordinary skill in the art will readily appreciate, however, that thevertical and longitudinal cross section of prism optics 25 a may eachhave any suitable radius of curvature or degree of decline such that thelight is distributed approximately 25–30 degrees to the left and rightof vertical axis A—A.

In FIG. 7C, a portion of optical surface 81 is shown in longitudinalcross-sectional view (along line B₃—B₃). Prism optics 25 b preferablyhave a longitudinal cross sectional profile that is generally convextoward light emitting diodes 12. More specifically, in the embodimentshown here, the longitudinal cross section of prism optics 25 b has aradius of curvature that is approximately 7.182 mm. In FIG. 7D, aportion of optical surface 81 is shown in vertical cross-sectional view(along line A—A). Prism optics 25 b have a vertical cross sectionalprofile that is generally convex toward light emitting diodes 12. Morespecifically, in the embodiment shown here, the vertical cross sectionof prism optics 25 b has a radius of curvature that is approximately31.965 mm. One of ordinary skill in the art will readily appreciate,however, that the vertical and longitudinal cross section of prismoptics 25 b may each have any suitable radius of curvature such that thelight is distributed approximately eight (8) degrees left to eight (8)degrees right of vertical axis A—A and approximately zero (0) degrees tofour (4) degrees up from longitudinal axis B₁—B₁.

In FIG. 7E, a portion of optical surface 90 is shown in longitudinalcross-sectional view (along line B₂—B₂). Prism optics 25 c preferablyhave a longitudinal cross sectional profile that is generally concavetoward light emitting diodes 12 with an incline angle k equivalent toapproximately 2.950 degrees up from the horizontal. More specifically,in the embodiment shown here, the longitudinal cross section of prismoptics 25 c has a radius of curvature that is approximately 30.000 mm.In FIG. 7F, a portion of optical surface 90 is shown in verticalcross-sectional view (along line A—A). In the embodiment shown here,prism optics 25 c preferably have a vertical cross-sectional profilethat is generally linear with an incline angle j equivalent toapproximately 2.592 degrees up from the horizontal. One of ordinaryskill in the art will readily appreciate, however, that the vertical andlongitudinal cross section or prism optics 25 c may each have anysuitable radius of curvature or degree of incline such that the light isdistributed approximately two (2) degrees down from longitudinal axisB₁—B₁ and approximately two (2) degrees right of vertical axis A—A.

As described hereinabove, in the embodiment shown, headlamp assembly 4comprises two high beam headlamps 170 in addition to two (2) low beamheadlamps 70 (see FIG. 1). In general, high beam headlamp 170 comprisesthe same components as low beam headlamp 70, namely, housing 6,reflector subassembly 11, a plurality of high-flux light emitting diodes12, planar substrate 9, a plurality of inner light transmissive members17, and drive circuit 5. However, rather than an outer lighttransmissive member 13 as disclosed supra, each high beam headlamp 170comprises an outer light transmissive member 113 as described infra.

FIG. 8 illustrates a longitudinal cross-sectional view of lighttransmissive member 113 along line X₂—X₂ (see FIG. 9) as provided in anindividual high beam headlamp 170. As can be seen in FIG. 8, lighttransmissive member 113 has an inner surface 121 and outer surface 122.Similar to light transmissive member 13, a plurality of annularextensions 20 corresponding to light emitting diodes 12 extends frominner surface 121. Annular extensions 20 are support mechanisms for theplurality of inner light transmissive members 17 in the same mannerdescribed above in connection with headlamp 70.

FIG. 9 shows a rear top plan view of outer light transmissive member113. Referring to FIG. 9, longitudinal axis of headlamp 170 is definedas line X₁—X₁, and vertical axis of headlamp 170 is defined as line Y—Y.

As can be seen here, high beam headlamp 170 is comprised of lighttransmissive member 113 is a lens with a plurality of optical elementsformed on inner surface 121. Specifically, and referring to FIG. 9,inner surface 121 comprises four distinct optical surfaces 180, 181,190, 191. Optical surfaces 180, 181, 190, 191 function as converging, orfocusing, lenses to satisfy the photometric and luminescencerequirements for high beam headlamps as set forth in SAE Standard J1383.In this embodiment for a high beam headlamp, optical surfaces 180, 181,190, 191 are linear prisms with a conic cross section, whereby eachprism is convex toward light emitting diodes 12 to function as aconvergent optic.

For example, referring again to FIG. 8, one embodiment of opticalsurfaces 180, 181, and 190 is illustrated. As shown, optical surface 180has a conic cross-sectional profile that is convex toward light emittingdiodes 12. Portions of optical surface 180 disposed inside annularextensions 20 collect collimated light rays from the corresponding innerlight transmissive member 17 and uniformly distribute the light rays ina horizontal direction, approximately six (6) degrees left and right oflongitudinal axis to X₁—X₁. Additionally, portions of optical surface180 disposed outside annular extensions 20 collect collimated light raysfrom reflector subassembly 11 and also uniformly distribute the lightrays approximately six (6) degrees left and right of vertical axis Y—Y.

In this embodiment, but not intending to be limiting, optical surface180 has radii of curvature that range from approximately 20 mm to 904 mm(a difference of 884 mm). However, one of ordinary skill in the art willreadily appreciate that optical surface 180 may have any suitable rangeof radii of curvature such that the light rays are distributedapproximately six (6) degrees left and right of vertical axis Y—Y.

Referring further to FIG. 8, optical surface 181 has a coniccross-sectional profile that is convex toward light emitting diodes 12.Portions of optical surface 181 disposed inside annular extensions 20collect collimated light rays from the corresponding inner lighttransmissive member 17 and uniformly distribute the light rays in ahorizontal direction, approximately three (3) degrees left and right ofvertical axis Y—Y. Additionally, portions of optical surface 181disposed outside annular extensions 20 collect collimated light raysfrom reflector subassembly 11 and uniformly distribute the light raysapproximately three (3) degrees left and right of vertical axis Y—Y.

In this embodiment, but not intending to be limiting, optical section181 has radii of curvature that range from approximately 48 mm to 842 mm(a difference of 794 mm). However, one of ordinary skill in the art willreadily appreciate that optical surface 181 may have any suitable rangeof radii of curvature such that the light rays are distributedapproximately three (3) degrees left and right of vertical axis Y—Y.

Referring further to FIG. 8, optical surface 190 preferably has a coniccross-sectional profile that is conic toward light emitting diodes 12.Portions of optical surface 190 disposed inside annular extensions 20collect collimated light rays from the corresponding inner lighttransmissive member 17 and uniformly distribute the light rays in ahorizontal direction, approximately nine (9) degrees left and right ofvertical axis Y—Y. Additionally, portions of optical surface 190disposed outside annular extensions 20 collect collimated light raysfrom reflector subassembly 11 and uniformly distribute the light raysapproximately nine (9) degrees left and right of vertical axis Y—Y.

In this embodiment, but not intending to be limiting, optical section190 has radii of curvature that range from approximately 7 mm to 821 mm(a difference of 814 mm). However, one of ordinary skill in the art willreadily appreciate that optical surface 190 may have any suitable rangeof radii of curvature such that the light rays are distributedapproximately nine (9) degrees left and right of vertical axis Y—Y.

Finally, in FIG. 10A, optical surface 191 is shown in longitudinalcross-sectional view (along line Z—Z) without light transmissive member17 and, in FIG. 10B, optical surface 191 is shown in verticalcross-sectional view (along line V—V) with light transmissive member 17.Optical surface 191, disposed only within the bottom center annularextension 20, collects collimated light rays from the correspondinginner light transmissive member 17 and uniformly distributes the lightrays in a horizontal direction, approximately fifteen (15) degrees leftand right of vertical axis Y—Y. Additionally, referring to FIG. 10B,optical surface 191 has a linear vertical cross-sectional profile with adecline angle h to distribute the light rays vertically approximatelyone (1) degree downward of longitudinal axis X₁—X₁.

In this embodiment, but not intending to be limiting, optical section190 has radii of curvature that range from approximately 23.09 mm to44.20 mm (a difference of 21.11 mm). Moreover, in this embodiment,decline angle h is equivalent to approximately 1.00 degree down from thehorizontal. However, one of ordinary skill in the art will readilyappreciate that optical surface 191 may have any suitable range of radiiof curvature, or decline angle h, such that the light rays aredistributed approximately fifteen (15) degrees left and right andapproximately one (1) degree downward.

In practice, when high beam headlamp 170 is switched on, low beamheadlamp 70 remains on to supplement the high beam pattern. Low beamheadlamp 70 provides supplemental light distribution below thehorizontal, for example, 2.5 degrees down and 12 degrees left and right,to satisfy the SAE requirements J1383 for a high beam pattern.

FIG. 11A illustrates a top plan view of housing 6 in one embodiment oflow beam headlamp 70. FIG. 11B illustrates a bottom plan view of oneembodiment of housing 6, and FIG. 11C illustrates a cross-sectional viewof one embodiment of housing 6 along line D—D. In the embodiments shownand described supra, housing 6 functions as the heat sink. Accordingly,in the embodiment shown, housing 6 is made of a single piece ofaluminum, either die cast or extruded. In an alternate embodiment, diecast zinc can be used for housing 6.

Housing 6 is exposed to the outside air, thereby allowing the heattransfer provided by housing 6 to be transferred to the air due toconvection. In addition, as shown in FIGS. 11B–11C, a plurality ofadjacent, vertically-oriented external cooling fins 16 are disposed onthe bottom of housing 6 to enhance the transfer of the heat generated bylight emitting diodes 12. In this way, the temperature of light emittingdiodes 12 and space 7 are kept sufficiently cool to prevent degradationof the brightness of low beam headlamp 70. By preventing degradation oflight emitting diodes 12, the transfer of heat via external fins 16 aidsheadlamp assembly 4 in meeting the requirements of SAE J1383 and thelegal criteria set forth in FMVSS 108.

In the embodiment shown, low beam headlamp 70 is also potted with anepoxy. This not only provides a greater heat sink and ability towithdraw thermal energy directly away from light emitting diodes 12, butalso provides protection for light emitting diodes 12 and planarsubstrate 9 from vibration, fatigue, and moisture.

Additionally, housing 6 also provides a mechanism to mount low beamheadlamp 70 onto vehicle 1, such as a truck, tractor and/or a trucktrailer. Moreover, apertures 15 are found at the bottom of housing 6.Apertures 15 are function as exit points for electrical wires to connectto circuitry outside low beam headlamp 70. In the embodiment shown, lowbeam headlamp 70 has three (3) apertures 15. One of ordinary skill inthe art will readily appreciate that apertures 15 can also be standardheadlamp terminals and can be arranged in a number of ways. As discussedabove, substrate 9 is disposed within space 7 and operatively mounted tohousing 6. Although not shown here, in an alternate embodiment, housing6 for high beam headlamp 170 has two apertures 15.

In an alternate embodiment (not shown), a separate heat sink 14 isutilized. In this embodiment, housing 6 can be made of a material thatdoes not have heat transfer properties, such as polycarbonate plastic.Heat sink 14 is made of aluminum, either die cast or extruded, or anyother material with similar heat transfer properties, such as die castzinc. Heat sink 14 is operatively mounted to the base of housing 6 andplanar substrate 9 is mounted to heat sink 14.

FIG. 12 shows one embodiment of drive circuit 5 in one embodiment ofheadlamp assembly 4. As can be seen, light emitting diodes 12, in bothheadlamp 70 and headlamp 170, are connected to a drive circuit 5 inseries/parallel; i.e. three strings of two light emitting diodes 12. Inthis way, a failure of any one string will cause a reduction in lightoutput, but not in the distribution of light.

In an embodiment of drive circuit 5 found in headlamp assembly, drivecircuit 5 is a current-regulating drive circuit with over-voltageprotection. Referring to FIG. 12, drive circuit 5 provides constantcurrent to three (3) parallel strings of light emitting diodes for two(2) inputs (high/low beam) in the following manner. Drive circuit 5comprises three of the below-described circuits—one for each parallelstring of light emitting diodes. Current is regulated through a voltagerange of approximately 9.5V to 16.0V. Current flows through either diode33 for high beam input, or diode 34 for low beam input, and is filteredby capacitor 36 before input to low drop out (LDO) current regulators 35a, 35 b, 35 c. LDO current regulators 35 a, 35 b, 35 c are enabled by asmall current input. Current regulation is established in LDO currentregulators 35 a, 35 b, 35 c by feedback resistor 38 located on the lowside of the light emitting diode load. The resistor value of feedbackresistor 38 determines current flow through the string of light emittingdiodes and is filtered by capacitors 37 a, 37 b, 37 c on the output ofLDO current regulators 35 a, 35 b, 35 c.

Referring further to FIG. 12, as current returns to ground, it passesthrough HEXFET® switching device 39, which is enabled on/off by anover-voltage sensing circuit. When operating in designed voltage range,approximately 9.5 V-16.0 V, HEXFET® switching device 39 is enabled onand will conduct. When the voltage exceeds upper design limit, a Zenerdiode sensing component conducts and causes a transistor to pull low(grounding) the gate of HEXFET® switching device 39. This actiondisables HEXFET® switching device 39 and disconnects the ground or(negative wire) from LDO current regulators 35 a, 35 b, 35 c and loadpart of circuit 5. When the voltage returns to design voltage range, theabove-described process reverses, turning the load and LDO currentregulators 35 a, 35 b, 35 c back on.

In the embodiment illustrated above, drive circuit 5 is mounted onsubstrate 9. However, in alternate embodiments, drive circuit 5 can beseparate from substrate 9 or even disposed outside one or both of lowbeam headlamp 70 and high beam headlamp 170. One of ordinary skill inthe art will recognize that alternate circuits with current regulationto protect the light emitting diodes can be used. For example, a circuitthat uses a switching power supply followed by a linear currentregulator could be employed.

FIG. 13A is a partial vertical cross-sectional view of one embodiment oflow beam headlamp 70 that illustrates the manner in which light emittedfrom light emitting diodes 12 is directed by reflector units 11 a andinner light transmissive members 17. FIG. 13B is a longitudinalcross-sectional view of outer light transmissive member 113 and innerlight transmissive member 17 in high beam headlamp 170, illustrating themanner in which light received from inner light transmissive members 17is directed by outer transmissive member 113.

FIG. 14, a diagrammatic, top plan view of vehicle 1, illustrates themanner in which headlamp assembly 4 emits light beams in a longitudinaldirection parallel to the longitudinal axis of vehicle 1. FIG. 14further illustrates an imaginary surface 8, upon which light beams areprojected. FIGS. 15A–15B illustrate the light pattern emitted by lowbeam headlamp 70 and high beam headlamp 170, respectively, ontoimaginary surface 8.

For each of the embodiments disclosed herein, the surfaces for reflectorunits 11 a and outer light transmissive members 13, 113 were designedand/or constructed using a Non-Uniform Rational B-Splines (NURBS) CADmodeling program, Rhinoceros 2.0 (McNeel Associates, 2001), and thefinal design and documentation was performed using Unigraphics CADsystem.

One of ordinary skill in the art will readily appreciate that a varietyof low beam and high beam headlamp arrays and arrangements are withinthe scope of this invention. For example, by selectively turning onportions of the light emitting diode headlamp assembly, it is possibleto vary the light output to produce not only a high or low beam, butalso a fog light or auxiliary high beam or driving light.

In addition, alternate light distribution patterns can be used. As thelumen output of LEDs increases as a result in technologicalimprovements, the additional output can be dispersed in directions thatsatisfy aesthetic or customer-specific light patterns, but that stillmeet legal and SAE standards.

Moreover, in an alternate embodiment of a light emitting diode headlampassembly according to the invention, a pair of combined low/high beamheadlamps comprising a plurality of light emitting diodes as a lightsource can be utilized. FIGS. 16A–B illustrate reflector subassembly 211in an alternate embodiment of the invention, namely a 7-inch roundcombined high/low beam headlamp 270. In this embodiment, two headlamps270 would be used to form a light emitting diode headlamp assemblyaccording to the invention.

Referring to FIGS. 16A–B, reflector subassembly 211 combines twelve (12)individual reflector units 211 a forming a circular arrangement suchthat each individual reflector unit 211 a corresponds to one of twelve(12) individual light emitting diodes 212. As in the previouslydisclosed embodiments, reflector units 211 a are parabolic reflectors.Approximately six (6) or seven (7) of light emitting diodes 212 areutilized to produce a low beam pattern for the headlamp assembly. Theremainder, approximately six (6) or seven (7) of light emitting diodes212 are utilized to produce a high beam pattern for the headlampassembly, all in a single headlamp unit. FIG. 16C illustrates thecorresponding circular arrangement of light emitting diodes 212 on acircular planar substrate 209.

In still another embodiment (not shown), a reflector subassemblycombines twelve (12) individual reflector units forming a circulararrangement such that each individual reflector unit corresponds to oneof twelve (12) individual light emitting diodes. Moreover, the size andshape of the combined high/low beam headlamp embodiments can vary. Forexample, the combined low/high beam headlamp can be rectangular,comprising a 2×5 array of light emitting diodes and a corresponding 2×5array of parabolic reflector units forming a reflector subassembly.Again, approximately five or six of light emitting diodes are utilizedto produce a low beam pattern for the headlamp assembly. The remainder,approximately five (5) or six (6), of light emitting diodes are utilizedto produce a high beam pattern.

Although, for convenience, the invention has been described primarilywith reference to specific embodiments, it will be apparent to those ofordinary skill in the art that the mirror assembly and the componentsthereof can be modified without departing from the spirit and scope ofthe invention as claimed.

1. A headlamp, comprising: a housing defining an inner surface and anouter surface; an outer light transmissive member adapted to engage withsaid housing, defining a three-dimensional space therebetween, saidouter light transmissive member defining a lens cover, with an inner andouter face, for said housing; a plurality of reflector units positionedwithin said space, said plurality of reflector units collimating a firstportion of said emitted light rays, forming first incident light rayssubstantially parallel to a longitudinal axis of said headlamp anddirected toward said lens cover; a corresponding plurality of high-fluxlight emitting diodes arranged at the base of said reflector units andoperatively mounted to a support member such that emitted light rays aredirected away from said support member; a plurality of inner lighttransmissive members adjacent to said outer light transmissive member,said plurality of inner light transmissive members collimating a secondportion of said emitted light rays, forming second incident light rayssubstantially parallel to said longitudinal axis and directed towardsaid lens cover, wherein each of said plurality of inner lighttransmissive members is fixedly secured to at least one alignmentmechanism such that each of said plurality of inner light transmissivemembers corresponds to one of said plurality of light emitting diodes,and wherein said at least one alignment mechanism comprises a pluralityof annular extensions corresponding to said plurality of inner lighttransmissive members, each of said annular extensions integral to saidinner face of said outer light transmissive member and extendinglaterally therefrom; and a heat dissipating mechanism; wherein saidheadlamp effectively emanates white light in any given direction.
 2. Aheadlamp according to claim 1 wherein each of said plurality of innerlight transmissive members is an aspheric lens.
 3. A headlamp,comprising: a plurality of light emitting diodes; a housing formed of amaterial for transferring heat away from said plurality of lightemitting diodes; an outer light transmissive member with an inner andouter face, said outer light transmissive member adapted to engage withsaid housing to define a three-dimensional space therebetween; a unitaryreflector subassembly positioned within said space, wherein saidreflector subassembly comprises an array of parabolic reflector units; acorresponding array of high-flux light emitting diodes as a lightsource; at least one inner light transmissive member adjacent to saidouter light transmissive member; at least one alignment mechanism,wherein said at least one inner light transmissive member is fixedlysecured to said at least one alignment mechanism such that said at leastone inner light transmissive member is aligned generally parallel tosaid outer light transmissive member and in front of said array of lightemitting diodes; and a driver circuit with a current regulationmechanism; and wherein said outer light transmissive member comprises atleast one optical surface to produce a wide light pattern extendingapproximately thirty (30) degrees left to approximately thirty (30)right of a vertical axis of said headlamp; a narrow light patternextending approximately eight (8) degrees left to approximately eight(8) degrees right of said vertical axis and approximately zero (0)degrees to approximately four (4) degrees up from a longitudinal axis ofsaid headlamp; and a concentrated point of light located approximatelytwo (2) degrees down from said longitudinal axis and approximately two(2) degrees right of said vertical axis.
 4. A headlamp according toclaim 3 wherein said at least one optical surface comprises arectangular array of prism optics formed on said inner face of saidouter light transmissive member.
 5. A headlamp assembly comprising: atleast two headlamps comprising a plurality of high-flux light emittingdiodes as a light source; each of said at least two headlampscomprising: a housing; an outer light transmissive member hermeticallysealed with said housing, thereby defining a three-dimensional space; aplurality of reflector units positioned within said space andoperatively arranged to correspond to said plurality of light emittingdiodes; at least one inner light transmissive member adjacent to saidouter light transmissive member; at least one alignment mechanism suchthat each of said at least one inner light transmission membercorresponds to one of said plurality of high-flux light emitting diodes;a heat dissipating mechanism; and a driver circuit with a currentregulation mechanism, said driver circuit operatively arranged to drivesaid plurality of light emitting diodes; and wherein said at least twoheadlamps includes two (2) low beam headlamps and two (2) high beamheadlamps and wherein each of said low beam headlamps comprises at leastone optical surface formed on said outer light transmissive member toproduce white light in a distribution pattern comprising: a wide lightpattern extending approximately thirty (30) degrees left toapproximately thirty (30) right of a vertical axis of said headlamp; anarrow light pattern extending approximately eight (8) degrees left toapproximately eight (8) degrees right of said vertical axis andapproximately zero (0) degrees to approximately four (4) degrees up fromsaid longitudinal axis; and a concentrated point of light locatedapproximately two (2) degrees down from said longitudinal axis andapproximately two (2) degrees right of said vertical axis.
 6. A headlampassembly according to claim 5 wherein said at least one optical surfacecomprises a rectangular array of prism optics formed on said inner faceof said outer light transmissive member.
 7. A headlamp, comprising: ahousing defining an inner surface and an outer surface; an outer lighttransmissive member adapted to engage with said housing, defining athree-dimensional space therebetween, said outer light transmissivemember defining a lens cover, with an inner and outer face, for saidhousing and wherein said outer light transmissive member has at leastone optical surface formed on said inner face of said outer lighttransmissive member; a plurality of reflector units positioned withinsaid space, said plurality of reflector units collimating a firstportion of said emitted light rays, forming first incident light rayssubstantially parallel to a longitudinal axis of said headlamp anddirected toward said lens cover; a corresponding plurality of high-fluxlight emitting diodes arranged at the base of said reflector units andoperatively mounted to a support member such that emitted light rays aredirected away from said support member; a plurality of inner lighttransmissive members adjacent to said outer light transmissive member,said plurality of inner light transmissive members collimating a secondportion of said emitted light rays, forming second incident light rayssubstantially parallel to said longitudinal axis and directed towardsaid lens cover, wherein each of said plurality of inner lighttransmissive members is fixedly secured to at least one alignmentmechanism such that each of said plurality of inner light transmissivemembers corresponds to one of said plurality of light emitting diodes;and a heat dissipating mechanism; wherein said headlamp effectivelyemanates white light in any given direction; and wherein said at leastone optical surface includes: a first optical surface for producing afirst light pattern extending approximately six (6) degrees left andright of a longitudinal axis of said headlamp; a second optical surfacefor producing a second light pattern extending approximately three (3)degrees left to approximately three (3) right of a vertical axis of saidheadlamp; a third optical surface for producing a third light patternextending approximately nine (9) degrees left to approximately nine (9)right of said vertical axis; and a fourth optical surface for producinga fourth light pattern extending approximately fifteen (15) degrees leftto approximately fifteen (1) degrees right of said vertical axis of saidheadlamp and approximately one (1) degree downward from saidlongitudinal axis.
 8. A headlamp according to claim 7 wherein said atleast one optical surface comprises a plurality of adjacent, linearprisms formed on said inner face of said outer light transmissivemember.
 9. A headlamp according to claim 8 wherein each of said linearprisms has a conic cross section and is generally convex toward saidplurality of light emitting diodes to function as a convergent optic.10. A headlamp, comprising: a plurality of light emitting diodes; ahousing formed of a material for transferring heat away from saidplurality of light emitting diodes; an outer light transmissive memberwith an inner and outer face, said outer light transmissive memberadapted to engage with said housing to define a three-dimensional spacetherebetween; a unitary reflector subassembly positioned within saidspace, wherein said reflector subassembly comprises an array ofparabolic reflector units; a corresponding array of high-flux lightemitting diodes as a light source; at least one inner light transmissivemember adjacent to said outer light transmissive member; at least onealignment mechanism, wherein said at least one inner light transmissivemember is fixedly secured to said at least one alignment mechanism suchthat said at least one inner light transmissive member is alignedgenerally parallel to said outer light transmissive member and in frontof said array of light emitting diodes; and a driver circuit with acurrent regulation mechanism; and wherein said outer light transmissivemember comprises at least one optical surface to produce a first lightpattern extending approximately six (6) degrees left and right of alongitudinal axis of said headlamp; a second light pattern extendingapproximately three (3) degrees left to approximately three (3) right ofa vertical axis of said headlamp; a third light pattern extendingapproximately nine (9) degrees left to approximately nine (9) right ofsaid vertical axis; and a fourth light pattern extending approximatelyfifteen (15) degrees left to approximately fifteen (1) degrees right ofsaid vertical axis of said headlamp and approximately one (1) degreedownward from said longitudinal axis.
 11. A headlamp according to claim10 wherein said at least one optical surface comprises a plurality ofadjacent linear prisms formed on said inner face of said outer lighttransmissive member.
 12. A headlamp according to claim 11 wherein eachof said plurality of linear prisms has a conic cross section and isgenerally convex toward said plurality of light emitting diodes tofunction as a convergent optic.
 13. A headlamp assembly comprising: atleast two headlamps comprising a plurality of high-flux light emittingdiodes as a light source; each of said at least two headlampscomprising: a housing; an outer light transmissive member hermeticallysealed with said housing, thereby defining a three-dimensional space; aplurality of reflector units positioned within said space andoperatively arranged to correspond to said plurality of light emittingdiodes; at least one inner light transmissive member adjacent to saidouter light transmissive member; at least one alignment mechanism suchthat each of said at least one inner light transmission membercorresponds to one of said plurality of high-flux light emitting diodes;a heat dissipating mechanism; and a driver circuit with a currentregulation mechanism, said driver circuit operatively arranged to drivesaid plurality of light emitting diodes; and wherein said at least twoheadlamps includes two (2) low beam headlamps and two (2) high beamheadlamps and wherein each of said high beam headlamps comprises atleast one optical surface formed on said outer light transmissive memberto produce white light in a distribution pattern comprising: a firstlight pattern extending approximately six (6) degrees left and right ofthe longitudinal axis; a second light pattern extending approximatelythree (3) degrees left to approximately three (3) right of said verticalaxis; a third light pattern extending approximately nine (9) degreesleft to approximately nine (9) right of said vertical axis; and a fourthlight pattern extending approximately fifteen (15) degrees left toapproximately fifteen (1) degrees right of said vertical axis of saidheadlamp and approximately one (1) degree downward from saidlongitudinal axis.
 14. A headlamp assembly according to claim 13 whereinsaid at least one optical surface comprises a plurality of adjacentlinear prisms formed on said inner face of said outer light transmissivemember.
 15. A headlamp assembly according to claim 14 wherein each ofsaid linear prisms has a conic cross section and is generally convextoward said plurality of light emitting diodes to function as aconvergent optic.
 16. A headlamp, comprising: a housing defining aninner surface and an outer surface; an outer light transmissive memberadapted to engage with said housing, defining a three-dimensional spacetherebetween, said outer light transmissive member defining a lenscover, with an inner and outer face, for said housing and wherein saidouter light transmissive member has at least one optical surface formedon said inner face of said outer light transmissive member; a pluralityof reflector units positioned within said space, said plurality ofreflector units collimating a first portion of said emitted light rays,forming first incident light rays substantially parallel to alongitudinal axis of said headlamp and directed toward said lens cover;a corresponding plurality of high-flux light emitting diodes arranged atthe base of said reflector units and operatively mounted to a supportmember such that emitted light rays are directed away from said supportmember; a plurality of inner light transmissive members adjacent to saidouter light transmissive member, said plurality of inner lighttransmissive members collimating a second portion of said emitted lightrays, forming second incident light rays substantially parallel to saidlongitudinal axis and directed toward said lens cover, wherein each ofsaid plurality of inner light transmissive members is fixedly secured toat least one alignment mechanism such that each of said plurality ofinner light transmissive members corresponds to one of said plurality oflight emitting diodes; and a heat dissipating mechanism; wherein saidheadlamp effectively emanates white light in any given direction; andwherein said at least one optical surface includes a first opticalsurface for producing a wide light pattern extending approximatelythirty (30) degrees left to approximately thirty (30) right of avertical axis of said headlamp, a second optical surface for producing anarrow light pattern extending approximately eight (8) degrees left toapproximately eight (8) degrees right of said vertical axis andapproximately zero (0) degrees to approximately four (4) degrees up froma longitudinal axis of said headlamp, and a third optical surface forproducing a concentrated point of light located approximately two (2)degrees down from said longitudinal axis and approximately two (2)degrees right of said vertical axis.
 17. A headlamp according to claim16 wherein said at least one optical surface comprises a rectangulararray of prism optics.
 18. A headlamp according to claim 16 wherein saidfirst optical surface comprises prism optics generally convex towardsaid plurality of light emitting diodes.
 19. A headlamp according toclaim 16 wherein said second optical surface comprises prism opticsgenerally convex toward said plurality of light emitting diodes.
 20. Aheadlamp according to claim 16 wherein said third optical surfacecomprises prism optics generally concave toward said plurality of lightemitting diodes.
 21. A headlamp, comprising: a housing defining an innersurface and an outer surface; an outer light transmissive member adaptedto engage with said housing, defining a three-dimensional spacetherebetween; a plurality of reflector units positioned within saidspace; a corresponding plurality of high-flux light emitting diodesarranged at the base of said reflector units and operatively mounted toa support member; a plurality of inner light transmissive membersadjacent to said outer light transmissive member; a plurality of annularextensions integral to said outer light transmissive member, whereinsaid plurality of inner light transmissive members are fixedly securedto said plurality of annular extensions; a heat dissipating mechanismfor transferring heat away from said plurality of light emitting diodes;and a driver circuit with a current regulation mechanism; wherein saidheadlamp effectively emanates white light in any given direction.
 22. Aheadlamp, comprising: a housing; an outer light transmissive memberadapted to engage with said housing to define a three-dimensional spacetherebetween; a plurality of reflector units positioned within saidspace; a corresponding plurality of high-flux light emitting diodes as alight source arranged at the base of said reflector units; a pluralityof inner light transmissive members adjacent to said outer lighttransmissive member; and a rectangular array of prism optics formed onsaid outer light transmissive member such that said headlamp produceswhite light in a distribution pattern comprising: a wide light patternextending approximately thirty (30) degrees left to approximately thirty(30) right of a vertical axis of said headlamp; a narrow light patternextending approximately eight (8) degrees left to approximately eight(8) degrees right of said vertical axis and approximately zero (0)degrees to approximately four (4) degrees up from a longitudinal axis ofsaid headlamp; and a concentrated point of light located approximatelytwo (2) degrees down from said longitudinal axis and approximately two(2) degrees right of said vertical axis.
 23. A headlamp, comprising: ahousing; an outer light transmissive member adapted to engage with saidhousing to define a three-dimensional space therebetween; a plurality ofreflector units positioned within said space; a corresponding pluralityof high-flux light emitting diodes as a light source arranged at thebase of said reflector units; a plurality of inner light transmissivemembers adjacent to said outer light transmissive member; and aplurality of adjacent linear optics formed on said outer lighttransmissive member such that said headlamp produces white light in adistribution pattern comprising: a first light pattern extendingapproximately six (6) degrees left and right of a longitudinal axis ofsaid headlamp; a second light pattern extending approximately three (3)degrees left to approximately three (3) right of a vertical axis of saidheadlamp; a third light pattern extending approximately nine (9) degreesleft to approximately nine (9) right of said vertical axis; and a fourthlight pattern extending approximately fifteen (15) degrees left toapproximately fifteen (1) degrees right of said vertical axis of saidheadlamp and approximately one (1) degree downward from saidlongitudinal axis.